Stretchable Foam Slit Design to Eliminate Cutting Waste
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Solution Overview
Problem
Current foam cutting methods result in significant material waste and environmental pollution due to the discarding of punched-out portions, which is not conducive to energy conservation, material reduction, and cost reduction.
Innovation Solution
A stretchable foam with a slit group design that allows for forming holes through stretching, minimizing material loss by creating slits and deforming them to form hole structures without cutting, and a cutting tool to implement this process efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional cutting methods are used to create holes in foam, then hole structures are formed, but significant material waste occurs
Solution Approach 1:
The patent changes the physical state and geometric parameters of the foam material by applying stretching force. The foam is stretched in a direction perpendicular to the slit, transforming the linear slit into a expanded hole structure. This parameter change (from unstretched to stretched state) converts the cutting process from material removal to material deformation, eliminating waste
Solution Approach 2:
Instead of cutting holes directly from the foam (traditional approach), the patent inverts the process by first creating slits and then stretching the foam to form holes. This reverse sequence transforms a subtractive manufacturing process into a deformative process, where the material is reshaped rather than removed
2Quantity of substance
If equal-sized foam pieces are cut according to dimensions, then functional needs are met, but material utilization decreases
Solution Approach 1:
The patent introduces dynamic stretching after the initial slit cutting. The foam is stretched to a predetermined extent to expand the slit into a hole structure. This dynamic process allows the final hole dimensions to be controlled by the stretching ratio rather than the initial cut dimensions, improving material utilization while maintaining dimensional control
3Ease of manufacture
If punched-out portions are discarded, then hole formation is achieved, but production costs increase
Solution Approach 1:
The patent converts what would normally be waste material (the portions around the slits) into useful structural elements. When the foam is stretched, the material between slits expands to form the walls of the hole structures, transforming potential waste into functional load-bearing elements that provide both hole formation and structural integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves near-zero cutting loss, improving material utilization, reducing costs, and decreasing environmental pollution while enhancing production efficiency and user comfort with stable, breathable hole structures.
Implementation Method 1
the foam is stretched according to the shape of the slit, and the slit is deformed through stretching
Data Source
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AI summary
The present invention provides a stretchable foam, furniture, and a cutting tool, relating to the technical field of foam production. The stretchable foam is provided with a slit group, and the slit group includes two rows of slits. Each row of slits includes multiple cutting units arranged at intervals. Each cutting unit includes a first straight edge and a second straight edge connected to each other, and the first straight edge and the second straight edge form an opening. The openings of the multiple cutting units in the first row of slits and the multiple cutting units in the second row of slits are arranged in opposite directions and are staggered in sequence. The adjacent first straight edge and second straight edge of two adjacent cutting units in the first row of slits are located within the opening of the same cutting unit in the second row of slits. The stretchable foam can reduce material waste, save costs, and improve production efficiency.